Nozzle for blow-molding stepped finish preform

ABSTRACT

A nozzle for a blow-molding process includes a first sealing portion and a second seating portion. A transition portion is positioned between the first sealing portion and the second sealing portion. The nozzle is configured such that upon engagement with a container preform having a longitudinal axis, the second sealing portion is positioned along the longitudinal axis at a different location than the first sealing portion.

PRIORITY

This application is a continuation of U.S. patent application Ser. No.16/802,483, filed Feb. 26, 2020, which claims the benefit of andpriority to U.S. Provisional Patent Application No. 62/810,852, filed onFeb. 26, 2019, the entirety of each application being incorporatedherein by reference.

FIELD

Embodiments of the present disclosure generally relate to the field ofplastic bottles and preforms. More specifically, embodiments of thedisclosure relate to a nozzle for blow-molding a container preform thatincludes a stepped interior surface.

BACKGROUND

Plastic containers have been used as a replacement for glass or metalcontainers in the packaging of beverages for several decades. The mostcommon plastic used in making beverage containers today is polyethyleneterephthalate (PET). Containers made of PET are transparent, thinwalled, and have the ability to maintain their shape by withstanding theforce exerted on the walls of the container by their contents. PETresins are also reasonably priced and easy to process. PET bottles aregenerally made by a process that includes the blow-molding of plasticpreforms which have been made by injection molding of the PET resin.

Advantages of plastic packaging include lighter weight and decreasedbreakage as compared to glass, and lower costs overall when taking bothproduction and transportation into account. Although plastic packagingis lighter in weight than glass, there is still great interest increating the lightest possible plastic packaging so as to maximize thecost savings in both transportation and manufacturing by making andusing containers that contain less plastic.

A plastic container for storing liquid contents typically includes abase that extends up to a grip portion suitable for affixing a label, aswell as providing a location for grasping the container. The gripportion generally transitions into a shoulder, which connects to a bell.The bell has a diameter that generally decreases as the bell extendsupward from the shoulder to a neck and a finish. The finish is adaptedto receive a closure, such as a bottle cap, to seal the contents withinthe interior of the plastic container.

In many instances, the closure includes a tamper evidence band that isdisposed around the perimeter of the finish. The tamper evidence bandgenerally remains positioned on the finish when an end-user loosens theclosure to access the contents within the container. As such, the tamperevidence band and the finish cooperate to indicate to the end-userwhether or not the closure has been previously loosened after beinginstalled by the manufacturer.

Advantages of plastic containers include lighter weight and decreasedbreakage as compared to glass, and lower costs overall when taking bothproduction and transportation into account. As such, there is acontinuous interest in creating the lightest possible plastic containerso as to maximize cost savings in both transportation and manufacturingby making and using containers that contain less plastic.

One difficulty that may be encountered when working with relativelylight plastic containers is damaging the preforms during theblow-molding process. In some instances, conventional equipment forblow-molding lightweight preforms into containers can crack, scrape, orotherwise damage the preforms, thereby rendering such preforms useless.For example, the relatively thin walls of a lightweight preform arepredisposed to cracking when a conventional nozzle for blow-molding thepreform is inserted into the finish portion of the preform. As such,there is a need for equipment suitable for forming the lightest possibleplastic containers without damaging the thin-walled preforms during theblow-molding process. Embodiments disclosed herein provide nozzles thatcan be engaged with lightweight preforms for forming the preforms intoplastic containers without damaging the finish portion or the thin wallsof the preforms.

SUMMARY

An apparatus for a nozzle is provided for engaging with lightweightpreforms for blow-molding the preforms into plastic containers withoutdamaging the finish portion of the preforms. The nozzle comprises afirst cylindrical portion including a first seal, a second cylindricalportion including a second seal, and a tapered portion between the firstand second cylindrical portions. The first and second cylindricalportions include diameters that are less than respective diameters ofinterior surfaces within the finish portion. The first and second sealsare disposed around respective circumferences of the first and secondcylindrical portions and configured to tightly engage with the interiorsurfaces of the preform while maintaining clearance between the nozzleand the interior of the finish portion. In some embodiments, the sealsare configured to stabilize an orientation of the preform after beingpressed onto the nozzle and facilitate conveying the preform along amanufacturing line. In some embodiments, the nozzle includes a taperedtip comprising a narrowing of the diameter of the first cylindricalportion forward of the first seal so as to provide clearance between thenozzle and the interior surface of the container preform. The taperedtip is configured to prevent damage to interior surfaces of a finishportion comprising the container preform during insertion of the nozzleinto the opening. The nozzle includes an opening whereby stretchingand/or blow-molding instruments may be inserted into the containerpreform.

In an exemplary embodiment, a nozzle for forming a container preforminto a plastic container comprises: a first cylindrical portionincluding a first seal; a second cylindrical portion including a secondseal; and a tapered portion between the first and second cylindricalportions.

In another exemplary embodiment, the nozzle further includes a taperedtip comprising a narrowing of a diameter of the first cylindricalportion forward of the first seal so as to provide clearance between thenozzle and an interior surface of the container preform. In anotherexemplary embodiment, the nozzle further comprises an opening wherebystretching and/or blow-molding instruments may be inserted into thecontainer preform. In another exemplary embodiment, the tapered tip isconfigured to prevent damage to interior surfaces of a finish portioncomprising the container preform during insertion of the nozzle into theopening.

In another exemplary embodiment, the first seal is disposed around acircumference of the first cylindrical portion and configured to tightlyengage with a first smooth interior surface of a finish portion of thecontainer preform; and wherein the second seal is disposed around thecircumference of the second cylindrical portion and configured totightly engage with a second smooth interior surface of the finishportion. In another exemplary embodiment, the first cylindrical portionincludes a diameter that is substantially less than an inner diameter ofthe first smooth interior surface so as to provide clearance between thefirst cylindrical portion and the first smooth interior surface. Inanother exemplary embodiment, the second cylindrical portion includes adiameter that is substantially less than an inner diameter of the secondsmooth interior surface so as to provide clearance between the secondcylindrical portion and the second smooth interior surface. In anotherexemplary embodiment, the first seal and the second seal are configuredto respectively press against the first smooth interior surface and thesecond smooth interior surface such that clearance is disposed betweenthe first cylindrical portion and the first smooth interior surface andbetween the second cylindrical portion and the second smooth interiorsurface. In another exemplary embodiment, the first seal and the secondseal comprise O-rings configured to tightly press againstmirror-polished interior surfaces within the finish portion.

In another exemplary embodiment, the tapered portion comprises atransition from a diameter of the second cylindrical portion to adiameter of the first cylindrical portion, the diameter of the firstcylindrical portion being less than the diameter of the secondcylindrical portion. In another exemplary embodiment, the taperedportion is configured to accommodate a decrease in diameter of aninterior surface of a finish portion comprising the container preform.

In an exemplary embodiment, a nozzle for forming a container preforminto a plastic container comprises: a first cylindrical portionincluding a first seal and a tapered tip; a second cylindrical portioncoupled to the first cylindrical portion by way of a tapered portion;and a second seal mounted onto the tapered portion.

In another exemplary embodiment, the first seal is disposed around acircumference of the first cylindrical portion and configured to tightlyengage with a first smooth interior surface of a finish portion of thecontainer preform; and wherein the second seal is disposed around acircumference of the tapered portion and configured to tightly engagewith a second smooth interior surface of the finish portion. In anotherexemplary embodiment, the first seal and the second seal are configuredto respectively press against the first smooth interior surface and thesecond smooth interior surface such that clearance is disposed betweenthe first cylindrical portion and the first smooth interior surface andbetween the second cylindrical portion and the second smooth interiorsurface. In another exemplary embodiment, the first seal and the secondseal comprise O-rings configured to tightly press againstmirror-polished interior surfaces within the finish portion.

in another exemplary embodiment, the first seal is configured toforcibly contact a first transition surface of the finish portion andthe second seal is configured to forcibly contact a second transitionsurface of the finish portion, the first transition surface having adiameter less than a diameter of the second transition surface. Inanother exemplary embodiment, the first seal and the second seal areconfigured to respectively contact the first transition surface and thesecond transition surface so as to stabilize an orientation of thecontainer preform after being pressed onto the nozzle. In anotherexemplary embodiment, the first seal and the second seal are configuredto maintain clearance between an interior of the finish portion and thenozzle. In another exemplary embodiment, the first seal and the secondseal are configured to maintain clearance between the container preformand equipment to which the nozzle is coupled.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates a side view of an exemplary container suitable forstoring pressurized contents;

FIG. 2 a side plan view of an exemplary embodiment of a preform suitablefor being blow-molded to form a container in accordance with the presentdisclosure;

FIG. 3 illustrates a close-up cross-sectional view of a sidewall portionof a finish comprising the preform illustrated in FIG. 2, according tothe present disclosure;

FIG. 4 illustrates a cross-sectional view of a container preformincluding a stepped interior surface that is engaged with an exemplaryembodiment of a nozzle for forming lightweight containers according tothe present disclosure;

FIG. 5 illustrates a close-up cross-sectional view of a sidewall portionof the preform of FIG. 4 that is engaged with an exemplary embodiment ofa nozzle for forming lightweight containers, in accordance with thepresent disclosure;

FIG. 6 illustrates a cross-sectional view of a container preformincluding a stepped interior surface that is engaged with an exemplaryembodiment of a nozzle for forming lightweight containers according tothe present disclosure;

FIG. 7 illustrates a close-up cross-sectional view of a sidewall portionof the preform of FIG. 6 that is engaged with an exemplary embodiment ofa nozzle for forming lightweight containers, in accordance with thepresent disclosure;

FIG. 8 illustrates a cross-sectional view of a container preformincluding a stepped interior surface that is engaged with an exemplaryembodiment of a nozzle for forming lightweight containers according tothe present disclosure; and

FIG. 9 illustrates a close-up cross-sectional view of a sidewall portionof the preform of FIG. 8 that is engaged with an exemplary embodiment ofa nozzle for forming lightweight containers, in accordance with thepresent disclosure.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstbottle,” may be made. However, the specific numeric reference should notbe interpreted as a literal sequential order but rather interpreted thatthe “first bottle” is different than a “second bottle.” Thus, thespecific details set forth are merely exemplary. The specific detailsmay be varied from and still be contemplated to be within the spirit andscope of the present disclosure. The term “coupled” is defined asmeaning connected either directly to the component or indirectly to thecomponent through another component. Further, as used herein, the terms“about,” “approximately,” or “substantially” for any numerical values orranges indicate a suitable dimensional tolerance that allows the part orcollection of components to function for its intended purpose asdescribed herein.

In general, there is a continuous interest in creating the lightestpossible plastic container so as to maximize cost savings in bothtransportation and manufacturing by making and using containers thatcontain less plastic. One difficulty often encountered when working withlightweight plastic containers is damaging the preforms during theblow-molding process. For example, the relatively thin walls of alightweight preform frequently are subject to cracking when aconventional nozzle for blow-molding the preform is inserted into thefinish portion of the preform. Embodiments disclosed herein providenozzles that can be engaged with lightweight preforms for blow-moldingthe preforms into plastic containers without damaging the finish portionof the preforms.

FIG. 1 illustrates a side view of an exemplary container 100 typicallyused for storing liquid contents, such as water, juice, and particularlycarbonated contents. The container 100 comprises a base 104 that extendsup to a grip portion 108. In some embodiments, the base 104 may be ofthe petaloid variety, although other configurations of the base may beincorporated into the container 100, without limitation, The gripportion 108 comprises a plurality of grip portion ribs 112 (i.e.,sidewall ribs). As illustrated in FIG. 1, the plurality of grip portionribs 112 generally vary in depth, and swirl or angulate around the gripportion 108. A label portion 116 is connected to the grip portion 108and comprises one or more label panel ribs (not shown). The label panelportion 116 transitions into a shoulder 124, which connects to a bell128.

In the embodiment illustrated in FIG. 1, the bell 128 comprises aplurality of design features 132. In other embodiments, however, thebell 128 may include various other design features, or may be smooth andgenerally unornamented. The bell 128 connects to a neck 136, whichconnects to a finish 140. As shown in FIG. 1, the bell 128 comprises adiameter that generally decreases as the bell 128 extends upward fromthe shoulder 124 to the neck 136 and the finish 140. The finish 140 isadapted to receive a closure, such as by way of non-limiting example, acontainer cap or closure 144, so as to seal contents within thecontainer 100. The finish 140 generally defines an opening that leads toan interior of the container 100 for containing a beverage, or othercontents, such as any of a variety of carbonated soft drinks. The finish140 may be of the Carbonated Soft Drink (CSD) variety or may beconfigured to receive closures suitable for sealing noncarbonatedcontents within the interior of the container 100.

As shown in FIG. 1, a tamper evidence closure 144 may be threadablyengaged with the finish 140 of FIG. 3. The closure 144 generallyincludes interior threads that are configured to engage with threadsdisposed on the finish 140, as described herein. During tightening ofthe closure 144 onto the finish 140, a plug seal of the closure 144extends into the opening of the container 100 and enters into a pressedrelationship with the finish 140 whereby contents may be sealed in theinterior of the container 100.

As further shown in FIG. 1, the closure 144 includes a tamper evidenceband 148 to provide an indication of whether or not the closure 144 hasbeen loosened after being installed by a manufacturer. In someembodiments, the tamper evidence band 148 may be attached to the closure144 by a multiplicity of thin connections. The tamper evidence band 148may include a cam that is configured to fixedly engage with a tamperevidence ledge disposed on the finished 140 during loosening of theclosure 144. Once the closure 144 is installed onto the finish 140 by amanufacturer and later an end-user loosens the closure 144, the camengages the tamper evidence ledge, breaking the thin connections betweentamper evidence band 148 and the closure 144. The tamper evidence band148 remains positioned on the tamper evidence ledge after the closure144 is removed from the container 100. As such, the tamper evidence band148 cooperates with the tamper evidence ledge to indicate to theend-user whether or not the closure 144 has been previously loosenedafter being installed by the manufacturer.

FIG. 2 illustrates an exemplary embodiment of a preform 160 suitable forbeing blow-molded to form a plastic bottle, such as the container 100,according to the present disclosure. The preform 160 preferably is madeof material approved for contact with food and beverages such as virginPET or recycled PET and can be of any of a wide variety of shapes andsizes. The preform 160 shown in FIG. 2 is of the type which will form a12-16 oz. beverage bottle, but as will be understood by those skilled inthe art, other preform configurations may be used depending upon thedesired configuration, characteristics and use of the final article. Thepreform 160 may be made by injection molding methods, withoutlimitation.

The preform 160 includes a finish portion 164 and a body portion 168,formed monolithically (i.e., as a single, or unitary, structure).Advantageously, the monolithic arrangement of the preform 160, whenblow-molded into a bottle, provides greater dimensional stability andimproved physical properties in comparison to a preform constructed ofseparate neck and body portions that are bonded together.

The finish portion 164 begins at an opening 172 to an interior of thepreform 160 and extends to and includes a tamper evidence ledge 176. Thefinish portion 164 is further characterized by the presence of one ormore threads 180 configured to provide a means to fasten a closure, suchas a cap, to the bottle produced from the preform 160. As such, thethreads 180 are configured to rotatably engage with similar threadsdisposed within the cap to provide a way to seal contents within thebottle. In the embodiment illustrated in FIG. 2, each of the threads 180generally extends along a section of the circumference of the finishportion 164 and approaches the tamper evidence ledge 176. Thus, when thethreads of a cap are engaged with the threads 180, and the cap isrotated in a clockwise direction, the cap advances toward the tamperevidence ledge 176.

With continuing reference to FIG. 2, each of the one or more threads 180begins at a thread star 184 and extends along an angular section of thefinish portion 164. The thread start 184 is configured to guide thethread 180 into a space, or valley, between adjacent threads of the capso as to threadably engage the cap with the finish portion 164. Further,the threads 180 generally are disposed adjacently to one another,separated by a valley 188, and are spaced uniformly around thecircumference of the finish portion 164. In some embodiments, whereinthree threads 180 are disposed around the finish portion 164, the threadstarts 184 of adjacent threads 180 are spaced at substantially120-degree intervals around the perimeter of the finish portion 164. Aswill be appreciated, however, more or less than three threads 180 may beincorporated into the finish portion 164 without deviating beyond thescope of the present disclosure.

In some embodiments, a plurality of gaps may be disposed in the threads180 and positioned uniformly around the perimeter of the finish portion164. Preferably, the gaps of adjacent threads 180 are vertically alignedso as to form channels extending longitudinally along the finish portion164. The channels advantageously operate to relieve pressure within thecontainer 100 when the container 144 is loosened. As will beappreciated, the channels may provide a direct route for gases escapingthe interior of the container 100, rather than the gases being forced totravel around the finish portion 164 between adjacent threads 180.

The body portion 168 includes a neck portion 192 that extends to atapered portion 196 of the body portion 168. The tapered portion 196comprises a smooth transition from a diameter of the neck portion 192 toa relatively smaller diameter of a cylindrical portion 200 of thepreform 160. The cylindrical portion 200 is a generally elongate memberthat culminates in an end cap 204. In some embodiments the body portion168 may be generally cylindrical, and the end cap 204 may be conical orfrustoconical and may also be hemispherical, and the very terminus ofthe end cap 204 may be flattened or rounded.

In some embodiments, a wall thickness of the cylindrical portion 200 maybe substantially uniform throughout the cylindrical portion 200 and theend cap 204. A wall thickness of the tapered portion 196, however,generally decreases from the wall thickness of the cylindrical portion200 to a relatively thinner wall thickness of the neck portion 192. Aswill be appreciated, the wall thickness of the cylindrical portion 200is relatively greater than the wall thickness of the neck portion 192 soas to provide a wall thickness at the desired dimensions of a finishedproduct after the preform 160 is blow-molded into the shape and size ofa bottle. As such, the wall thickness throughout most of the bodyportion 168 will depend upon the overall size of the preform 160 and thewall thickness and overall size of the resulting container.

FIG. 3 illustrates a close-up cross-sectional view of a sidewall of thefinish portion 164 illustrated in FIG. 2. As will be appreciated, thefinish 164 comprises a cylindrical body that begins at the opening 172to the interior of the container 100 and extends to and includes thetamper evidence ledge 176. The finish portion 164 includes a bevel 208disposed at the beginning of the opening 172. The bevel 208 isconfigured to enter into sliding contact with a plug seal of the closure144 so as to prevent contents from leaking out of the container 100formed from the preform 160. In some embodiments, the bevel 208 operatesto guide the plug seal onto a sealing surface 212 disposed on aninterior of the finish portion 164. In general, the bevel 208 and thesealing surface 212 comprise portions of the interior of the finishportion 164 that extend circumferentially around the opening 172.

As will be appreciated, the sealing surface 212 must comprise asufficiently smooth surface capable of cooperating with the plug seal toretain contents under pressure, such as carbonated contents, within thecontainer 100. To this end, it is contemplated that the sealing surface212 may be highly polished so as to be substantially free of surfacedefects and thus conditioned to form a tight seal with the plug seal ofthe closure 144. Preferably, the sealing surface 212 is to be polishedto a degree of smoothness that is commonly associated with a mirrorfinish. As such, it is contemplated that the sealing surface 212comprises a mirror polished region along the interior of the finishportion 164. Further, in some embodiments, the bevel 208 may also beconditioned to comprise a mirror polished region at the beginning of theopening 172. Any of various techniques may be used to mirror polisheither or both of the sealing surface 212 and the bevel 208, withoutlimitation.

As shown in FIG. 3, the sealing surface 212 extends away from the bevel208, deeper into the opening 172 to a transition surface 216. Thetransition surface 216 comprises a region within the interior of thefinish portion 164 wherein the interior diameter of the opening 172generally narrows from the diameter of the sealing surface 212 to asmaller diameter of a handing surface 220. In the embodiment illustratedin FIG. 3, the transition surface 216 comprises a reverse curve surfacethat includes a concave portion 224 that extends from the sealingsurface 212 and joins with a convex portion 228 that extends to thehanding surface 220. As will be recognized, the handling surface 220includes a diameter of the opening 172 that is configured to receivevarious forms of equipment used to configure the preform 160 into thecontainer 100.

It is contemplated that the transition surface 216 is to be capable ofcooperating with the plug seal of the closure 144 to form a tight sealbetween the closure 144 and the container 100. In some embodiments, theconcave portion 224 may be configured to forcibly receive an end of theplug seal so as to form a tight seal therebetween. Further, in someembodiments, the convex portion 228 may be configured to forciblyreceive the end of the plug seal. As such, the transition surface 216may include a smooth surface that is polished similarly to the sealingsurface 212. It is envisioned that the transition surface 216 may bemirror polished, as described hereinabove with respect to the sealingsurface 212.

Moreover, in some embodiments, the plug seal of the closure 144 may beconfigured to extend into the opening such that the plug seal cooperateswith the handling surface 220 to seal the container 100. In suchembodiments, the plug seal may include a sidewall shape that mates withthe concave and convex portions 224, 228. As will be appreciated,therefore, the handling surface 220 may be mirror polished similarly tothe sealing surface 212 and the transition surface 216. It iscontemplated that mirror polished surface may be achieved by way of anyof various suitable polishing techniques, such as mechanical machiningand buffing, chemical treatments, plasma treatments, and the like,without limitation.

In some embodiments, such as the illustrated embodiment of FIG. 3, asecondary transition surface 244 may be disposed between the handlingsurface 220 and an interior surface 248 of the body portion 168. Ingeneral, the secondary transition surface 244 comprises a region withinthe interior of the finish portion 164 wherein the interior diameter ofthe opening 172 narrows from the diameter of the handling surface 220 toa smaller diameter of the interior surface 248. In the embodimentillustrated in FIG. 3, the secondary transition surface 244 comprises areverse curve surface that includes a concave portion 252 that extendsfrom the handling surface 220 to a convex portion 256 that extends tothe interior surface 248.

In some embodiments, the secondary transition surface 244 may beconfigured to cooperate with the plug seal of the closure 144 to form atight seal between the closure 144 and the container 100 suitable forstoring pressurized contents, such as carbonated beverages, within thecontainer 100. As such, the concave portion 252 may be configured totightly receive an end of the plug seal to form a tight sealtherebetween. In some embodiments, the convex portion 256 may beconfigured to forcibly receive and compress the end of the plug seal. Tothis end, the secondary transition surface 244 preferably includes asmooth surface that is polished similarly to the sealing surface 212. Itis envisioned that the secondary transition surface 244 may be mirrorpolished, as described hereinabove with respect to the sealing surface212.

In some embodiments, the plug seal of the closure 144 may be configuredto extend into the opening 172 such that the plug seal extends beyondthe secondary transition surface 244 and thus cooperates with theportion of the interior surface 248 near the convex portion 256. In someembodiments, the interior surface 248 may have a diameter that tightlycompresses the end of the plug seal to seal the pressurized contentswithin the container 100. It is contemplated that, in some embodiments,the plug seal may include a sidewall profile that mates with the concaveand convex portions 252, 256. As such, the interior surface 248preferably is mirror polished similarly to the mirror polish of thesealing surface 212. As disclosed hereinabove, the mirror polishedsurface may be achieved by way of any of various suitable polishingtechniques, such as mechanical machining and buffing, chemicaltreatments, plasma treatments, and the like, without limitation.

In the embodiment illustrated in FIG. 3, the surfaces 212, 220, 248generally comprise a stepped interior of the finish portion 164. Assuch, the stepped interior comprises a graduated narrowing of theopening 172 that extends from the bevel 208, through the finish portion164, to the tamper evidence ledge 176. It is contemplated that thestepped interior comprises multiple sidewall portions of the finish 164that may be configured to advantageously minimize the quantity of resincomprising the finish portion 164, as compared to finish portionscomprising a substantially uniform diameter.

In some embodiments, the stepped interior may be configured tocompressibly receive a plug seal of the closure 144 that comprisesgraduated seals configured to tightly engage with the graduatednarrowing of the opening 172. For example, the stepped interior caninclude one or more sealing surfaces that are each configured to tightlyengage with one of the graduated seals of the plug seal to contribute toforming a tight seal between the closure 144 and the container 100. Aswill be appreciated, therefore, the graduated seals of the plug sealgenerally include diameters that are suitable for engaging with thegraduated narrowing of the opening 172 so as to seal pressurizedcontents, such as carbonated beverages, within the container 100. It iscontemplated that the one or more sealing surfaces comprisemirror-polished surfaces that are joined together by transitionsurfaces. Further, the transition surfaces are contemplated to comprisemirror-polished surfaces that cooperate with the one or more seals ofthe plug seal so as to contribute to forming the tight seal between theclosure 144 and the container 100.

In the exemplary embodiment shown in FIG. 3, the sealing surface 212 isconfigured to compressibly receive a first seal comprising the plugseal, and the handing surface 220 is configured to compressibly receivea second seal of the plug seal. Further, the interior surface 248 may beconfigured to compressibly receive a third seal comprising the plugseal. According, the sealing surface 212 includes a first diameterconfigured to tightly compress the first seal of the plug seal, and thehandling surface 220 includes a second diameter configured to tightlycompress the second seal. The interior surface 248 includes a thirddiameter configured to tightly compress the third seal of the plug seal.As will be appreciated, the third diameter is equal to or less than thesecond diameter, and the second diameter is equal to or less than thefirst diameter. Further, the transition surface 216 comprises a changein diameter of the opening 172 that transitions from the first diameterof the sealing surface 212 to the second diameter of the handlingsurface 220. The secondary transition surface 244 comprises a change indiameter of the opening 172 that transitions from second diameter of thehandling surface 220 to the third diameter of the interior surface 248.As disclosed hereinabove, the transition surfaces 216, 244 comprisemirror-polished surfaces that may be formed by way of any of varioussuitable polishing techniques.

Turning now to FIG. 4, a nozzle 260 for blow-molding the preform 160into a container is shown inserted into the finish portion 164 andengaged with the stepped interior. The nozzle 260 generally is acylindrical member coupled with other blow-molding equipment 262 andconfigured to tightly engage with the graduated narrowing of the opening172. The nozzle 260 includes an opening 264 whereby instruments may beinserted into the preform 160 for stretching and/or blow-molding thepreform 160 into the container 100. A first seal 268 and a second seal272 are disposed around the circumference of the nozzle 260 andconfigured to tightly engage with the smooth surfaces inside the finishportion 164. In some embodiments, the first and second seals 268, 272comprise O-rings that are configured to tightly press against themirror-polished surfaces of the finish portion 164 without damaging thesurfaces or the walls of the finish portion 164. As such, it iscontemplated that the preform 160 may be pressed onto the nozzle 260 andretained thereon during being conveyed along a manufacturing line.

In the illustrated embodiment of FIGS. 4-5, the nozzle 260 includes afirst cylindrical portion 276 and a second cylindrical portion 280. Thefirst cylindrical portion 276 comprises a diameter suitable for pressingthe first seal 268 against the interior surface 248, and the secondcylindrical portion 280 has a diameter suitable for pressing the secondseal 272 against the handling surface 220. As best shown in FIG. 5, theseals 268, 272 preferably contact the surfaces 248, 220 whilemaintaining an advantageously degree of clearance between the surfaces248, 220 and the first and second cylindrical portions 276, 280. As willbe appreciated, preventing contact between the cylindrical portions 276,280 of the nozzle 260 and the surfaces 248, 220 obviates any damageoccurring to the mirror-polished surfaces of the finish portion 164.

With reference to FIG. 5, the sealing surface 212 is surrounded by athin-walled region 284 of the finish portion 164. In the case oflightweight preforms, such as the preform 160, the thin-walled region284 is susceptible to being damaged by contact with conventionalblow-molding nozzles. As such, the diameter of the second cylindricalportion 280 is configured to be substantially less than the innerdiameter of the sealing surface 212, thereby providing clearance betweenthe second cylindrical portion 280 and the sealing surface 212. Further,engaging the first and second seals 268, 272 with the surfaces 248, 220,as described herein, provides clearance between the finish portion 164and the blow-molding equipment 262. It is contemplated that preventingcontact between the sealing surface 212 and the cylindrical portion 280,as well as preventing contact between the finish portion 164 and theblow-molding equipment 262 prevents any stress being applied to thethin-walled regions 284 of the finish portion 164. As will beappreciated, therefore, in the embodiment of FIGS. 4-5, damage to thethin-walled region 284 of the finish portion 164 is substantiallyeliminated.

In the embodiment of the nozzle 160 illustrated in FIGS. 4-5, a taperedportion 288 is disposed between the first and second cylindricalportions 276, 280, and a tapered tip 292 is disposed forward of thefirst seal 268. As will be appreciated, the tapered portion 288 and thetapered tip 292 comprise decreases in the diameter of the nozzle 160that are configured to accommodate the stepped interior of the preform160. As shown in FIG. 5, the tapered portion 288 comprises a transitionfrom the diameter of the second cylindrical portion 280 to the smallerdiameter of the first cylindrical portion 276. Thus, the tapered portion288 accommodates the change in diameter of the interior of the finishportion 164 occurring across the transition surface 244 between thehandling surface 220 and the interior surface 248. The tapered tip 292generally comprises a narrowing of the diameter of the first cylindricalportion 276 forward of the first seal 268 so as to provide clearancebetween the nozzle 260 and the interior surface 248 of the preform 160.The tapered tip 292 is not limited to comprising a linearly taperingdiameter of the nozzle 260, as shown in FIG. 5, but rather other shapesare contemplated. For example, in some embodiments, the tapered tip 292may comprise an inwardly rounded portion of the cylindrical portion 276.It is contemplated that the tapered tip 292 preferably is configured toprevent damage to the mirror-polished surfaces inside the finish portion164 during insertion of the nozzle 260 into the opening 172.

As will be appreciated, forcibly pushing the preform 160 onto the nozzle260, as shown in FIG. 4, may cause the tapered portion 288 to contactthe transition surface 244 inside the finished portion 164. It iscontemplated that while the first and second seals 268, 272 tightlyengage with the mirror-polished surfaces 248, 220, contact between thetapered portion 288 and the transition surface 244 may operate tostabilize the orientation of the preform 160 on the nozzle 260. In someembodiments, such contact between the tapered portion 288 and thetransition surface 244 may be deemed acceptable due to the relativelythick sidewall of the preform 160 surrounding the transition surface244. It should be noted, however, that any contact between the nozzle260 and the preform 160, other than by way of the seals 268, 272, standsa likelihood of blemishing the transition surface 244.

It is contemplated that, in some embodiments, blemishing of thetransition surface 244, even if minor, may be undesirable. FIG. 6illustrates a cross-sectional view of the preform 160 engaged with anexemplary embodiment of a nozzle 300 that is configured to avoidblemishing any of the mirror-polished surfaces inside the finish portion164 of the preform 160. The nozzle 300 is similar to the nozzle 260 ofFIG. 4, with the exception that the nozzle 300 includes seals that areconfigured to stabilize the orientation of preform 160 on the nozzle 300without blemishing the finish portion 164. As such, the nozzle 300generally is a cylindrical member coupled with other blow-moldingequipment 262 and configured to tightly engage with the interior of thefinish portion 164. The nozzle includes an opening 304 through whichinstruments may be extended into the interior of the preform 160 forstretching and/or blow-molding the preform 160 into the container 100.The nozzle 300 includes a first seal 308 and a second seal 312 that aredisposed around the circumference of the nozzle 300. It is contemplatedthat the first and second seals 308, 312 comprise O-rings, or othersimilar devices, configured to tightly press against the mirror-polishedsurfaces within the finish portion 164 without damaging the surfaces orthe weakening the walls of the finish portion 164. As will beappreciated, therefore, the preform 160 may be pressed onto the nozzle300 and retained thereon during being conveyed along a manufacturingline.

As shown in FIG. 6, the nozzle 300 includes a first cylindrical portion316 and a second cylindrical portion 320 that share an interveningtapered portion 324. A tapered tip 328 extends forward of the firstcylindrical portion 316. The second cylindrical portion 320 comprises adiameter of the nozzle 300 that is less than the diameter of the sealingsurface 212. The diameter of the second cylindrical portion 320 is sizedto allow the nozzle 300 to be extended into the opening 172 of thefinish portion 164 without the nozzle 300 contacting the sealing surface212. Similarly, the first cylindrical portion 316 comprises a diameterof the nozzle 300 that is less than the diameter of the handing surface220 so as to prevent contact between the nozzle 300 and the handlingsurface 220.

With continuing reference to FIG. 6, the tapered portion 324 and thetapered tip 328 comprise decreases in the diameter of the nozzle 300that are configured to prevent contact between the nozzle 300 and thestepped interior of the preform 160. The tapered portion 324 generallycomprises a transition from the diameter of the second cylindricalportion 320 to the smaller diameter of the first cylindrical portion316. As such, the tapered portion 324 accommodates the change indiameter of the interior of the finish portion 164 occurring across thetransition surface 216 between the sealing surface 212 and the handlingsurface 220. The tapered tip 328 comprises a narrowing of the diameterof the first cylindrical portion 304 forward of the first seal 308 so asto prevent the nozzle 300 from contacting the transition surface 244 andthe interior surface 248 of the preform 160. As discussed in connectionwith the tapered tip 292, the tapered tip 328 is not limited to thespecific shape illustrated in FIG. 6, but rather other shapes arecontemplated. It is envisioned that the tapered tip 328 may beimplemented with any shape that is found to prevent damage to themirror-polished surfaces inside the finish portion 164 during insertionof the nozzle 300 into the opening 172.

As best shown in FIG. 7, the first seal 308 is coupled with the nozzle300 between the first cylindrical portion 316 and the tapered tip 328,such that the first seal 308 forcibly contacts the transition surface244 when the preform 160 is pressed onto the nozzle 304. Similarly, thesecond seal 312 is coupled with the tapered portion 324, such that thesecond seal 312 forcibly contacts the transition surface 216 when thepreform 160 is pressed onto the nozzle 304. It should be recognized,therefore, that while the first seal 308 tightly engages with theminor-polished surface 220, forcible contact of the seals 308, 312 withthe transition surfaces 244, 216 stabilize the orientation of thepreform 160 on the nozzle 300, as well as ensuring that clearanceremains between the preform 160 and the equipment 262. It iscontemplated, therefore, that the nozzle 300 advantageously facilitatespressing the preform 160 onto the nozzle 300 for being conveyed along amanufacturing line, as well as stretching and/or blow-molding thepreform 160 into the container 100, without any damage or blemishesbeing imparted to the sidewalls and mirror-polished surfaces of thefinish portion 164.

FIGS. 8-9 illustrate an exemplary embodiment of a nozzle 340 forblow-molding the preform 160 of FIG. 3 into a container, such as thecontainer 100. Similar to the nozzles described hereinabove, the nozzle340 is configured to be inserted into the finish portion 164, parallelto the longitudinal axis 266 of the preform 160 and engaged with thestepped interior of the preform 160. The nozzle 340 comprises a firstcylindrical portion 320 that may be coupled with other blow-moldingequipment 262. The cylindrical portion 320 transitions to a secondcylindrical portion 344 configured to accommodate the diameter of thehandling surface 220. The nozzle 340 includes a tapered portion 348 thatjoins the second cylindrical portion with a third cylindrical portion352. The third cylindrical portion 352 includes a diameter configured toaccommodate the inner diameter of the interior surface 248 of thepreform 160. The third cylindrical portion 352 extends to tapered tip328 that includes an opening 304 whereby instruments may be insertedinto the preform 160 for stretching and/or blow-molding the preform 160into the container 100. The tapered tip 328 is configured to extendsinto the interior of the preform 160 without damaging the surfaces 212,220, 248 or the sidewall of the finish portion 164.

As best shown in FIG. 9, a circular edge 360 is disposed between thefirst and second cylindrical portions 320, 344. The circular edge 360 isconfigured to forcibly contact the transition surface 216 of the finishportion 164. Preferably, the circular edge 360 has a diameter suitableto contact the transition surface 216 while providing clearance betweenthe first cylindrical portion 320 and the sealing surface 212. Upon thenozzle 340 being inserted into the finish portion 164, the circular edge360 digs into the material comprising the transition surface 216,thereby establishing a tight seal between the nozzle 340 and theinterior of the preform 160. As such, it is contemplated that thecircular edge 360 may be sharpened or remain blunt, as desired. Further,the first cylindrical portion 320 generally, and the circular edge 360in particular, may comprise any rigid material suitable for digging intothe material comprising the transition surface 216.

In general, the circular edge 360 is configured to be pressed againstthe transition surface 216 such that the force of contact is directedparallel to the longitudinal axis 266, along the sidewall of the finishportion 164. As will be appreciated, directing the contact forceparallel to the sidewall of the finish portion 164 allows for tightersealing between the nozzle 340 and the preform 160, thereby facilitatinggreater internal pressures within the preform 160 without cracking thethin-walled region 284 of the finish portion 164 during stretchingand/or blow-molding the preform 160 to form the container 100. Further,the nozzle 340 may include a seal 308 that is disposed around thecircumference of the third cylindrical portion 352 and configured toguide the nozzle 340 during entering the interior of the preform 160. Itis contemplated that the seal 308 may comprise an O-ring, or othersimilar device, configured to tightly press against the mirror-polishedinterior surface 348 within the finish portion 164 without damaging thesurfaces or the weakening the walls of the finish portion 164. As willbe appreciated, therefore, the preform 160 may be pressed onto thenozzle 340 and retained thereon during being conveyed along amanufacturing line.

As described hereinabove, the thin-walled region 284 surrounding thesealing surface 212 of lightweight preforms, such as the preform 160, issusceptible to being damaged by contact with conventional blow-moldingnozzles. Outward forces on the thin-walled region 284, due to forciblecontact between the surface 212 and a conventional nozzle or internalpressure during blow-molding the preform 160, tends to damage thesealing surface 212 and/or cause stress-failures within the thin-walledregion 284. The nozzle 340 eliminates such outwardly directed forces byengaging circular edge 360 with the transition surface 216 inside thefinish portion 164. As will be appreciated, sealing the circular edge360 against the transition surface 216 counteracts any outwardlydirected force components that may arise during stretching and/orblow-molding the preform 160 to form the container 100. As such, agreater internal pressure within the preform 160 may be used to form thecontainer 100 without harming the thin-walled region 284 of the finishportion 164. Further, it is contemplated that engaging the circular edge360 with the transition surface 216 obviates any need for sealing thenozzle 340 or other blow-molding molding equipment 262 against atop-most surface 242 of the preform 160, which eliminates exertingdamaging forces on the thin-walled region 284 of the finish portion 164during stretching and/or blow-molding the preform 160 to form thecontainer 100.

Turning again to FIG. 3, the tamper evidence ledge 176 comprises arounded upper portion 232 and a substantially flat lower portion 236. Aswill be appreciated, the rounded upper portion 232 facilitates passingthe tamper evidence band 148 of the closure 144 over the tamper evidenceledge 176 during assembly of the closure 144 onto the container 100. Theflat lower portion 236 is configured to retain the tamper evidence band148 positioned below the tamper evidence ledge 176 during loosening ofthe closure 144. For example, when the closure 144 is initiallyinstalled onto the container 100 by a manufacturer, the tamper evidenceband 148 easily passes over the tamper evidence ledge 176 due to therounded upper portion 232. When an end-user later loosens the closure144, the flat lower portion 236 retains the tamper evidence band 148below the tamper evidence ledge 176, causing the tamper evidence band148 to break loose from the closure 144. Thus, the flat lower portion236 of the tamper evidence ledge 176 and the tamper evidence band 148 ofthe closure 144 cooperate to indicate to the end-user that the closure144 has not been previously loosened after being installed by themanufacturer. It should be understood, however, that the tamper evidenceledge 176 is not limited to being coupled with tamper evidence bands, asdescribed above, but rather the tamper evidence ledge 176 may beconfigured to operate with any of various devices for indicating whetheror not the container has been previously opened.

Disposed between the tamper evidence ledge 176 and the threads 180 is ahandling valley 240 that extends circumferentially around the finishportion 164. The handling valley 240 comprises a portion of the finishportion 164 that has a wall thickness and a diameter that aresubstantially similar to the wall thickness and diameter of the neckportion 192, below the tamper evidence ledge 176. As such, the handlingvalley 240 and the neck portion 192 advantageously enable grippingfingers to engage with and support the container 100 duringair-conveying the container 100 along a manufacturing assembly. Forexample, a first pair of gripping fingers can extend into the handlingvalley 240 to support the container 100 at a first station of amanufacturing line. Then, upon being conveyed to a second station, asecond pair of gripping fingers can extend around the neck portion 192,below the tamper evidence ledge 176, while the first pair of grippingfingers are removed from the handling valley 240. Similarly, uponarriving at a third station, a third pair of gripping fingers can engagewith the handling valley 240 while the second pair of gripping fingersare removed from the neck portion 192. Thus, the container 100 can betransported along the manufacturing line by alternatingly engaginggripping fingers with the handling valley 240 and the neck portion 192.

As will be appreciated, the handling valley 240 provides a separationbetween the tamper evidence ledge 176 and the threads 180 suitable forreceiving the pair of gripping fingers, as described above. In general,the separation must be large enough to allow the gripping fingers toeasily pass between the tamper evidence ledge 176 and the threads 180.As such, any of various separations, greater than the width of thegripping fingers, may be disposed between the tamper evidence ledge 176and the threads 180, without limitation and without deviating beyond thescope of the present disclosure.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A nozzle for a blow-molding process, the nozzlecomprising: a first sealing portion; a second sealing portion; and atransition portion positioned between the first sealing portion and thesecond sealing portion, the nozzle configured such that upon engagementwith a container preform having a longitudinal axis, the second sealingportion is positioned along the longitudinal axis at a differentlocation than the first sealing portion.
 2. The nozzle of claim 1,wherein a seal of the first sealing portion is disposed around acircumference of the first sealing portion.
 3. The nozzle of claim 2,wherein the seal of the first sealing portion is in the form of anO-ring.
 4. The nozzle of claim 1, wherein a seal of the second sealingportion is disposed around a circumference of the second sealingportion.
 5. The nozzle of claim 4, wherein the seal of the secondsealing portion is in the form of an O-ring.
 6. The nozzle of claim 1,wherein one of the first and second sealing portions includes a circularedge as a seal.
 7. The nozzle of claim 6, wherein the circular edge is ablunt circular edge.
 8. The nozzle of claim 1, wherein the nozzlefurther defines an opening configured to permit the insertion of ablow-molding instrument therethrough.
 9. The nozzle of claim 1, whereinthe first and second sealing portions are cylindrical, and wherein thesecond sealing portion has a larger outer diameter than the firstsealing portion.
 10. A nozzle for a blow-molding process, the nozzlecomprising: a first sealing portion; and a second sealing portion, thenozzle configured such that upon engagement with a container preformhaving a sealing surface disposed on an interior of the preform finishadjacent a preform opening, no portion of the nozzle contacts thesealing surface.
 11. The nozzle of claim 10, further including atransition connecting the first sealing portion with the second sealingportion.
 12. The nozzle of claim 10, wherein the second sealing portionis a tapered sealing portion.
 13. The nozzle of claim 12, wherein a sealof the second sealing portion is disposed around a circumference of thesecond sealing portion.
 14. The nozzle of claim 10, wherein the nozzlefurther defines an opening configured to permit the insertion of ablow-molding instrument therethrough.
 15. The nozzle of claim 10,wherein the first and second sealing portions are cylindrical, andwherein the second sealing portion has a larger outer diameter than thefirst sealing portion.
 16. A nozzle for a blow-molding process, thenozzle comprising: a first cylindrical portion with a first seal; asecond portion with second seal, wherein the second portion is one of acylindrical portion or a tapered portion.
 17. The nozzle of claim 16,wherein the first seal is in the form of an O-ring.
 18. The nozzle ofclaim 16, wherein the second seal is in the form of an O-ring.